Manufacture of rayon yarn



ug. 25, 1942. A. L. JACKSON MANUFACTRE OF RAYON YARN Filed July 24, 1939 2 Sheets-Sheet l Aug. 25, 1942. A. L. JACKSON 2,293,981

MANUFACTURE OF RAYON YARN Filed July 24, 1959 2 sheets-sheet 2 Patented Aug. 25, 1942 Arthur L. Jackson, West Asheville, N. C., assignor to American Enka Corporation, Enka, N. C., a

corporation of Delaware Application July 24, 1939, Serial No. 286,294

13 Claims. (Cl. 18-8) This invention relates to rayon and to a process of and apparatus for producing rayon yarn. More particularly the invention is directed due to the resistance encountered in the coagulating bath and, too, only relatively gradual systo the production of rayon in which the lilay ments or threads thereof have a non-systemati denier variation in the form of nubs. The production of rayon yarns or threads and the utilization of the same in the formation of various types of fabrics has presented many problems due in part t denier variations oc-r curring in the nished yarns or threads as prepared and the normal operations involved -in the manufacture of knitted and Woven fabrics. most from the very inception of the rayon industry, these problems were recognized and there has lbeen a constant and progressive advance in the art, as a result of which rayon fabrics` are now offered generally in competition with other standard fabrics. However, during the past few years it has been found Athat while` slight imperfections in the yarns, filaments or threads in the form of denier variations are objectionable, novel effects in a finished fabric may be produced if the filaments or yarns are spun in a manner to produce accentuated denier 1 variations as distinguished from the objection-4 able imperfections. y

In view of this discovery, considerable activity tematic denier-variations in. the thread can be had -by such a process because rapid movement of the spinneret creates a prohibitorymotion in the bath. Furthermore, the use of rayon yarns or threads having systematic denier variations is not entirely satisfactory in that undesirable and somewhat monotonous pattern effects exist in fabrics made therefrom. v

In the United States Letters Patent of Gustav A. M. Heim,vNo. 2,220,403, it is proposed to produce rayon filaments, yarns and threads in which the denier variations thereof are non-uniform in length and occurrence. Furthermore, Gustav A. M. Heim in his patent points out that his invention contemplates the formation of rayon filaments which have denier variations of 'a relatively pronounced character land that such variations are substantially free of systematic recurrence. i

This invention contemplates the formation of rayon yarns, filaments or threads, for convenwas instigated with a view to providing processes and apparatus for efficiently producing varying denier or nub yarns which would formL novel and desirable fabrics when Woven or knitted.

It was suggested that the manufacture of rayon laments with intentional systematic deiner var-` iations be effected vby supplying the spinning solution to the spinnerets in a systematically irregular manner. Additionally, it was suggested that the same result be attained by applying a drag or braking action to the thread during its passage from the spinneret to the drawing off device. Further, it has been proposedy to prol duce such denier variations in rayon threads by causing the spinneret during the spinning operationto alternately approach and retract from the drawing oi device. Nevertheless, each of the heretofore proposed methods failed in one or more respects to accomplish the intended result. In the process inwhich the occurrence of denier variations is effected by the varying of the length of the thread passage between the spinneret and the drawing -oi device, among other disadvantages, the alternate approach to and retraction of the spinneret from the drawlng oidevice lowers the quality of the thread 5 ience hereinafter referred to as filaments, which have denier variations thatare of apronounced character and non-uniform so that the thickened or "nub portions are substantially free'of systematic recurrence.

It' is an object of this invention a mechanism by which rayon filaments may be elcientlymanipulated during the spinningpf, the same for producing denier variationswhich,

are very pronounced and non-systematic in occurrence. f i

The mechanism contemplated by this invent tion in its specific preferred .embodiment comy prises a chain lwhich is movable upon a' flat support and provided withcam blocks secured in an irregularly adjusted manner'to the chain links for actuating connecting rods which 4in turn mov` pivoted arms each of which carries a freely rotatable roller or friction guide for effecting 'a variationin the path of travel of succeeding portionsof the respective'laments being propelled thereover. 'y l Additionally this invention has as an `object the provision of a'y process and apparatus for the production of rayon filaments whereby novel effects will be produced in fabric'i'n which they are incorporated, the novel effects resulting from the non-systematic variations in the denier-'of the la'ments and the 'character of the ffnubs formed at varying intervals.

The present process and `apparatus contemplate forming nubs" in.v theA yarn by passing vto Vprovide i I 4laments-from a spinneret substantially verti- The filaments are drawn off. by means of a positively driven godet at a point remote from the spinneret relative to the posil tion of the rollers. The first roller is mounted for a slow movement away from the second roller and a quick return and the "nubs are formed on succeeding portions of the filaments adjacent the spinneret.

'I'he effects produced in materials wholly or partly fabricated of laments having non-sys- 4 tematic denier variations are particularly pleasing because it has been found that such materials whendyed, printed or otherwise colored have varying dyeing characteristics which result in the attainment of multitudinous and unpredictable effects.

Other objects and advantages will be apparent from the following detailed description when considered in connection with the accompanying drawings wherein:

Figure 1 is a view in side elevation of a por tion of one form of apparatus constructed in accordance with the present invention and c Figure 2 is a transverse sectional view through the machine shown in Figure 1 illustratingthe rollers for thev laments formed by one of the spinnerets together with the mechanism for supporting and moving one of the rollers.

In referring to the drawings in detail, the numeral I designates a spinneret positioned as shown in a coagulating bath II which extends i along the entire length of the spinning machine.

A plurality of spinnerets III are positioned at spaced intervals within the coagulating bath. From a, suitable source (not shown) a spinning solution is caused to be extruded from each of the spinnerets III to form filaments I2 in accord- 1 ance with any of the well known practices. In the 4case of a wet spinning process asillustrated, the laments as formed are withdrawn substantially vertically from the coagulating bath II. This is .accomplished by passing the laments to and around a freely rotatable roller I3, after which they are .caused to descend substantially vertically to and around a second freely rotatable roller I4 located in close proximity `to said first roller I3. lOne set of these rollers I3 and I4 is provided for cooperation with each spinneret III. After the bundle of laments I2 has passed .around the second roller I4, itis led to a respective draw-off godet I5 which is positively driven by any suitable means. The speed at which the filaments are withdrawn is controlled and determined by the R. P. M. of the godet I5 and the `collecting device (not shown).

An important aspect of the present invention is the position and location of the set of rollers I3 and I4 with respect to the spinneret -III and the godet I6. Rollers' I3 and I4 are located just above the spinning bath II but spaced a material distance from their respective godets/ I5 for a purpose to be hereinafter more fully discussed. Each roller I3 is carried at the free end of one of `a series of pivoted levers I6, the respective levers being pivotally secured to a` bracket II which is in turn bolted to a portion of ,the machine frame. Both bracket II and lever I6 are provided with a series of apertures through corresponding apertures without the necessity for bodily moving the lever.

The movement of the lever I6 about its axis, which is the bolt I9, is brought about by the action of cams 20 attached to a lmoving chain 2l, which cams successively engage a unit 22 which transmits the lifting action of the cams to the lever I6.

The chain 2| is supported and driven by sprockets 23 and 24 which in turn are keyed to shafts 25 and 26 journaled at 21 and 28. Journals 21 and 28 are attached to upstanding L-bars 29 spaced apart by channel bars 30 and 3l which extend the length of the'machine and act to maintain the two sprockets in spaced relation. The channel bar 3l acts as a housing for the lower run of chain 2| and the upper channel bar 30 acts as a runway therefor to maintain the same horizontal for the length of its upper run.

On the shaft 25 to which is keyed the sprocket 23 there is also keyed a sprocket 32 adapted to be connected to a suitable source of power (not shown) so that the sprockets and the chain carried thereby may be driven. `'I'he cams 26 are attached to alternate links of the chains 2|, and although the configuration of each cam conforms to every other cam, the spaces therebetween are varied by mounting the cam on the chain at variousl points along its length, as is clearly shown in Figure 1.

At spaced intervals along the upper run of the chain and overlying the cams are a, plurality of units 22 which transmit the motion imparted thereto by the cams to each lever I6. While a machine made in accordance with the present invention may involve various numbers of 'units e. g. 54 to 120 of the type disclosed, since each is identical in operation a single one will be described. 'I'he unit 22 comprises a connecting rod 33 having a bifurcated end 34 into the recesses of which a portion of lever I6 is received and held by bolt 35. The connecting rod is guided in its reciprocating path by bearing 36, filter bridge channel'31, spring stop 38 and bearing 39 eachattached to the machine frame. A -rubber ring 46 is mounted upon the upper surface of bearing 36 and encircles the connecting rod 33. Ring 4l acts to absorb the shock resulting from the enextremity of connecting rod 33 there is another bifurcated member- 43 into the recess of which Is placed a freely rotatable roller 44 acting as a cam follower. The position of cam follower 44 is directly above the path of travel of the cams 23 in their movement along the upper run of the chain.

In order to maintain the cam follower 44 at the proper position above` the chain 2l so that the cam follower 44 will lie in the ,path of the cams when the shoulder of bifurcated member 34 is resting against the rubber ring 40. and consequently, the arm I6 is at the lower limit of its oscillating path, the connecting rod 33 is made in two sections connected together by a turnbuckle 45.

In the operation of the spinning machine after the chain has been\set inmotion by connection to a source of power driving sprockets 32, and

after the usual pumps for causing the extrusion of filaments have been started and `the filaments are being drawn off around rollers AI3 and I4,

the lever I6 will oscillate in a path selected by their movement along the upper run of the chain as indicated by the arrow in Figure l. Due to the character of the cam surfaces and the speed of the chain, the upward movement of the connecting rods is gradual as the cams pass under respective cam followers. At the upper limit of each cam the cam follower is suddenly released bringing spring 42 into play to cause the lever I6 to abruptly return to its lower position. This operation willbe repeated as each cam 20 carried by the chain 2| engages each of the rollers 44, but it will be noted that the intervals between successive engagements will vary according to `why the present invention is a substantial improvement over past practices, it has been determined that the instant apparatus does provide a variegated and desirable product commercially satisfactory in the market. Probably due to the fact that the roller I3 is located vertically above spinneret I and adjacent the spinning bath II, the formation of appreciably sized short .nubs is-eiected near the spinneret I0 in the bath. The vertically rapid drop of the lever 'I6 carrying roller I3 will releasethe tension on the filaments momentarily, but long enough to form the nub while the slow rise will not materially alter the shape thereof. The long passage of the filaments from the second idler roller I 4 to the godet I5 will act t0` set the nubs in the filaments and the tension therebetween will be substantially uniform so that the space between the nubs on the filaments will be of even denier. Because of the intermittant non-systematic actuation of lever I6, the recurrence of the "nubs will be likewise non-systematic. More,- over, due to the varyingdistances between the cams 20, the vibrations'of the unit 22 will vary and effect different sized and shaped nubs thereby accentuating the variegated effects.

It is to be understood that various minorv `changes may be made in the details of the machine disclosed without departing from the spirit of the invention, e. g., in place of the freely rotatable rollers I3 and I4, friction thread guides may be substituted. Additionally, nubs of different thicknesses may be Vproduced 'either through the adjustability of the fulcrum of the lever I6, or through adjustment of the turnbuckle 45. While the invention applies particularly to filaments of irregularly varying denier produced by the wet or coagulation method and composed of reconstituted cellulose, such as viscose or cuv prammonium silk; it may be applied likewise to having as a ba'se cellulose acetate or other cel-f lulose derivatives.

It is intended that the process described, except'for that portion thereof relating to the nonsystematic production of irregularly varying denier, shall be conducted according to the well known practices in the art.

The methods and apparatus described above are merely representative and it is intended to include all methods and forms of apparatus as will fall within the scope of the following claims.

What is claimed is:

1. An apparatus for producing rayon filaments `comprising in combination means for forming filaments, a driven godet, a lever movable in an. arcuate path, a freely rotatable roller mounted on said lever, a second freely rotatable roller mounted in a fixed position in the path Vof the filaments between the godet and the first roller, and means to oscillate said lever so as to vary the distance between said first roller and said second roller while maintaining the distance between the second roller and godet constant.

2. An apparatus for producing rayon filaments comprising in combination means for forming filaments, a driven godet, a freely rotatable roller therebetween, a second freely rotatable roller for said filaments between said godet and said first roller,v said first roller being movable within a path with respect to said second roller to vary the distance therebetween, and means to actuate said first roller, said last named means path, and single means for moving each of said rollers at irregularly recurring intervals independently of each other.

4. An apparatus for producing rayon filaments comprising a plurality of means for l forming bundles of filaments, a driven godet for each bundle forming means, a freely rotatable roller for respective bundles in their path between said bundle forming means and said driven godet, each of said rollers being movable in a. restricted path, and a long endless 'conveyor having irregularly spaced cams lthereon for succ essively effecting the movement of each of said rollers at irregularly recurring intervals.

5. An apparatus for producing rayon filaments comprising a plurality of means for forming bundles of filaments, a driven godet for each bundle forming means, a freely rotatable roller for respective bundles in the1r path between 'said bundle forming means and said driven godet, each 'of said rollers being movable in a restricted path, means having a cam follower thereon connected to each roller, and a long endless conveyor havingl irregularly spaced cams thereon for successively contacting each of said cam followers at irregularly recurring intervals, thereby to actuate said rollers. Y

6..In an apparatus for producing rayon filaments including means for forming bundles of filaments, a driven godet and an oscillating guide for each bundle of filaments in theirpath of travel intermediate said forming means and the y l guide having said guide freely rotatably mounted thereon, means including a cam follower attached to each lever, and a driven conveyor operating adjacent said cam followers, said conveyor having irregularly spaced cams thereon each adapted to contact each of said followers independently of each other to actuate each said lever at irregularly recurring intervals.

7. In an apparatus for producing rayon dlaments including means for forming bundles of filaments, a driven godet and an oscillating guide for each bundle of filaments in their path of travel intermediate said forming means and the driven godet, an oscillating lever for each said guide' having said guide freely rotatably mounted thereon, means for effecting an adjustment of the path cf oscillation of said lever, means including a cam follower attached to each lever, a driven conveyor operating adjacent said cam followers, said' conveyor having irregularly spaced cams thereon each adapted to contact each of said followers independently of each other to actuate each said lever at irregularly recurring intervals.

8. In an apparatus for producing rayon'illa-` ment producing machine having a. freely rotatable roller thereon mounted on a member movable in a path, comprising means including a cam follower connected to said member, a driven ments including means for forming bundles of filaments, a driven godet and an oscillating guide for each bundle of filaments in their path ment of the path of oscillation of said lever,

means including a cam follower attached to each lever, a driven conveyor operating adjacent said cam follower, said conveyor having irregularly spaced cams thereon each adapted to contact and slowly raise and abruptly release each of said cam followers independently of each other to actuate said lever at irregularly recurring intervals, and a meansconstantly urging said cam followers into the path of said cams.

9. An apparatus for producing 4rayon filaments having variable nubs'V therein comprising means for forming a bundle of filaments, a driven godet located at a point remote from said filament forming means, a freely rotatable roller mounted for reciprocation substantially vertimounted in a xed position in close proximity to said first roller and substantially vertically Y therebelow, and means to actuate said nrst roller with respect to said second rollerat irregularly recurring intervals. y

10. An operating mechanism forA a rayon iilaendless chain operating adjacent said cam follower, cams on said chain adapted to4 engage said follower, and means constantly urging said follower into the path of said cams, said cams being connected to alternate' links of said chain irregularly spaced.

11. An operating mechanism for a. rayon filament producing machine having a freely rotatable roller thereon mounted. on a member movable in a path, comprising means including a cam follower connected to said member, a driven endless chain operating adjacent said cam follower, cams on said chain adapted to engage said follower. means constantly urging said follower in the direction of said chain, and means to support a run of said chain, the upper surface of said cams sloping upwardly away from the direction of movement of said chain, said cams being connected to alternate links of said chain at different points onthe said chain.

12. An operating mechanism for a rayon filament producing machine having a freely rotatable roller thereon mounted on a member movable in a path comprising a cam follower on said member, a driven endless chain. operating adjacent said cam follower, cams on said chain adapted to engage said follower, means constantly urging said follower into the path of said cams, a support for a run of said chain and means enclosing another run of-said chain, said cams being connected to alternate links of said chain at irregularly spaced intervals.

13. A process for the production of rayon threads having variable nubs therein comprising extruding filaments vertically through a spinneret into a coagulating bath, directly drawing the formedthread substantially vertically and without friction, from the spinneret while in a plastic state under tension, deflecting said thread from its vertical path at a point remote from said bath, slowly increasing the,distance of said point of deflection from said bath at irregularly recurring intervals at a rate of speed insufficient to materiallyv alter the cross-section of said thread, and suddenly decreasing the distance of said point of deflection from said bath at the end of each said intervals, whereby nubs" are formed in the plastic thread adjacent the spinneret, and setting the nub formation in the thread by causing the thread to pass through a long path of` travel prior to collection.

ARTHUR L. JACKSON. 

